Method of fabricating structural elements



Jan. 3,' 1939-. R. BURKE 2,142,109

IETHOD 0F FABRICATING STRUCTURAL ELEMENTS Filed April 23, 1937 5 Sheets-Sheet l METHOD 0F FABRIGATING STRUCTURAL ELEMENTS Filed April 23, 1937 5 Sheets-Sheet 2 Jan. 3, 1939. R L BURKE 2,142,109

METHOD OF FABRICATING STRUCTURAL ELEMENTS Filed April 25, 193'? 5 Sheets-Sheet 3 Jan. 3, 1939. R, L. BURKE 2,142,109 f METHOD OF FABRICATING STRUCTURAL ELEMENTS f Filed April 23, 1937 5 Sheets-Sheet 4 L/ @Jud/3M@ Patented Jan. 3', i939 UNITED STATES PATENT OFFICE 2142109 HETHGD OF FABBICATING STRUCTURALy ELEMENTS f Y l Richard L. Burke, Swarthmore, Pa., assigner to Sun Shipbuilding Dry Dock Company, Cheltcr, Pa., a corporation o! Pennsylvania Application April 28, 1937, Serial No. 138,498 3 Claims. (Cl. 11S-e112) This invention relates to a method and apparatus for the fabrication of structural elements from metal plates and shapes by welding. From a more speciilc standpoint, this invention relates 5 to a method and apparatus for fabricating bulkheads, bottom and side shell and deck plating panels, etc. for ships from metal plates and shapes adapted to act as stiiieners, longitudinals, etc.

lil Heretofore it has been the practice to fabricate various structures, such as bulkheads, bottom shell, side shell and decks from plates and shapes, as stiffeners, longitudinals, etc. by riveting or welding the plates and shapes together.

l5 Such procedure is difficult of accomplishment, more particularly in the proper lining up of the plates and shapes, and especially where the plates and shapes are secured by welding, inasmuch as it is difficult, li not impossible, to prevent disi tortion resulting from the heat of welding. Such procedure has been found further disadvantageous from the standpoint oi time and labor.

Now, in accordance with this invention, a

method and apparatus has been developed with 25 which the plates and shapes comprising a given structural element, such as a ships bulkhead, may be easily and accurately fabricated, with a minimum of time and labor, to a point such that they require only to be placed in position and se- 3@ cured.

The method and apparatus in accordance with this invention are especially adaptable to the fabrication of ship bulkheads and bottom shell, side shell, and deck plate panels, etc. for ships 35 formed from a series of plates and stiiieners,

longltudinals, etc.' In following the procedure and with use of the apparatus the necessary shapes are secured to the plates by welding, and

the component plates vare welded together to i form a complete element ready for placing in position and securing.

The method and apparatus in accordance with this invention is especially advantageous in the forming of structural elements for ships, in that l 45 the shapes are, without dimculty, secured to the plates with a full metal to metal contact and with avoidance of warping of the plates usually resulting from welding. Further, the platesy are secured together with avoidance of warping due 50 to the welding heat to the end that, on cornpletion, the shapes and plates forming the element are integrally related and the element as a whole is true and without distortion.

The details of the method in accordance with W this invention and its practice will be described and clariiied in connection with a detailed descrlption of the structure of the apparatus, all with reference to the accompanying drawings, in which a preferred embodiment oi the apparatus in form for the fabrication of, for example, bulkheads for ships has been illustrated, and in which:

rFigure 1 is a side elevation, partly in section, oi.' an apparatus in accordance with this invention and adapted for practice of the method in accordance with this invention.

Figure 2 is a transverse view, partly in section, showing vmechanism for lining and holding the stiieners to plates, for tack-welding, in the Iormation of a bulkhead.

Figures 3 and 4 are views of details of con-- struction of the subject ci Figure 2.

Figure 5 is a transverse view, partly in section, showing mechanism for holding and welding plates in the formation of a bulkhead.

Figure 6 is a view showing details of construction ci the subject oi Figure 5.

The apparatus in accordance with this invention, shown generally in Figure l ci the drawings, comprises three essential elements adapted, ,25 respectively, in the formation, for example, of a bulkhead, for the lining and preliminary attachment of stiffeners to plates, for the 'welding of the stiiieners to the plates and for the welding of the plates together.

The three essential elements of theapparatus are indicated in Figure l by the characters A,

B and C.,

The elements A, B and C are progressively located and are supported from a bed or foundation D, which serves to support a series of castors 2 forming a bed adapted to support and facilitate the passage oi.' plates through the apparatus.

The element A, as has been indicated, functions for the alignment and preliminary secur- 4G ing of stlfieners 3 to the plates This element, the essential details of which are more particularly shown in Figures 2-4, comprises a series oi rams, each comprising a pneumatic or hydraulic cylinder t within which is a piston provided with a piston rod 6. The series of rams extend transversely of the apparatus and are arranged adjacent to one another.

On the lower end oi each ci the piston rods 6 50 is a head l having a centrally located dependent iiange 8 and a boss 9 depending from its edge. The depending boss 9 is tapped for the passage of a threaded screw I0 squared at its outer end 10i engagement by a wrench. A counterweight y 35 is formed opposite to the boss l to balance the boss and cause the head to remain level.

Passing through each of the heads and in alignment with a face of the flange I are a pair oi drop pins II, II. The drop pins II, II are provided, at their upper ends, with pins adapted to engage the upper side of the head when the head is lifted and are bored intermediatetheir ends for the passage of pins to maintain them in a raised position when the heads are lifted in order to provide clearance for the placing and removal of a shape with respect to the heads.

A heavy I-beam I2, supported from the foundation D and accurately levelled, extends beneath the several rams.

In the operation of the element A, a plate, supported mainly on the castors 2, is positioned with that portion of it to which a stiilener is to be secured overlying and supported by the I-beam I2, all with the heads 'I in elevated position and with the drop pins I I carried by the heads, respectively, in raised position to allow clearance. A stiffener 3 is placed on the plate in rough alignment and the heads `I brought down against the upper edge of the stiffener. The drop pins II .are then lowered and the face of the stifiener is locked securely against them and the depending flanges 8 by means of the threaded screws Il. which, as has been indicated, will be operated by, for example, a ratchet wrench. This brings the stiilener into accurate alignment as the flanges 8 and the drop pins Il are in alignment with each other. Pressure is then applied to the heads 'l by means of the pneumatic cylinders 5 and the lower edge of the stiilener is forced into metal to metal engagement with the surface of the plate.

The stiil'ener is then tack-welded to the surface of the plate at spaced points, as indicated at I3 in Figure 3.

The securing of a stiil'ener to the surface of the plate having been accomplished,y the plate is moved forward and other stitfeners as may be required are similarly secured to it. When the required number of stieners has been Isecured to the plate, it is then moved forward over the bed of castors 2 to the element B, in which the securing of the stiieners to the plate by welding is completed.

The element B comprises essentially a tilting table I4, to which the plate is secured, and a Welder I5 carried by a gantry I6 and capable of rrlzsverse movement with respect to the tilting The tilting table Il, which extends transverselyv ,at an angle of about 45 or other desired angle,

to the right or to the left.

The gantry I 6, from which the Welder I5 is supported, may be of any suitable construction running on rails arranged at opposite sides of the apparatus. The Welder may be of any usual or desired type. Thus, it may be an electric Welder of the type marketed by the Linde Air Products Company.

The Welder will be mounted on the gantry II for transverse movement and, for example, may be supported from a trolley 2l adapted for movement transversely of the apparatus on rails 22 anarco earriedbythegantry Il. Thewelderwillbe adjustable vertically by means of a screw II, by which it is suspended from trolley 2|. The trolley 2I will carry the necessary supplies for the welder, as melt or ilux In a tank 28 and wire 42 on a reel 2l. The melt or ux will be suitably delivered, for the welding operation, through a tube 2l, and the wire will be suitably led to the welder from the reel 2l. Electric current will be led to the welder through cables x supported from the trolley 2 I.

In the operation of the element B, the stiileners having been tack-welded to a plate in the element A, the plate and stiileners will be moved onto the tilting table Il, which, for the reception oi the plate, will be level with the bed of castors, and the plate will be aligned thereon and secured thereto by means of clamps 2l engaging the opposite edges of the plate. When the plate has been aligned on and secured to the tilting table, the tilting table will be tilted, by operation of the motor Ii, for example, to the left, at an angle of 45. The welder will then be brought down, at one end oi' a stin'ener, to the juncture oi.' the stiifener and plate and, operating transversely of the plate, will llet-weld the stiener to the plate from end to end, as shown, for example, at 2l, lgure 1. s The welding operation will be repeated for the welding from end to end of each of the stieners. For the welding of the stiii'eners, respectively, with ther table and supported plate tilted as shown in Figure 1, it will only be necessary to adjust the vertical position oi the welder and to mov'e the gantry Il to bring the Welder in proper relation with the several stilleners, respectively.

When the welding of the stlileners from end to end on one side has been completed, with the table Il tilted to the left, as shown in Figure l, the table is tilted correspondingly to the right and the fillet-welding? of the other side oi the stin'eners accomplished. When the welding of the stiilfeners has been completed, the tilting table Il is brought to a level, the clamps 26 removed, and the plate passed on over the bed of castors 2 to the element C, in which a plurality of plates are butt-welded together.

The element C, which, as has been indicated, functions in connection with the butt-welding together oi' plates to which stiffeners have been secured for the formation of a completed bulkhead, comprises a series of rams extending transversely of the apparatus in two parallel rows and a welder carriedon a trolley and mounted for movement transversely of the apparatus between the parallel rows of rams.

The element C, shown in Figure l, with respect to the elements A and B, is, more particularly, shown in Figures 5 and 6.

The rams, respectively, comprise pneumatic and hydraulic cylinders 2l, within which are pistons and to which are connected rods 29, carrying on their lower ends yokes or bifurcated heads Il. The heads Il are secured to the rods 29 by means of pins 52. Beneath the heads 30 are positioned heavy I-beams 3i, 3| in line with the bed of castors 2, and for the support of the plates to be welded together.

Between the I-beams 2l, 3| are a pair of supports 32, 22 mounted on screw jacks 33, 33 and arranged to engage the edge portions oi' a pair of plates to be welded and to provide means whereby plates oi' different thickness may be brought to a level.

The welder 34 is carried' on a screw 35 depend- 1| of the jacks ing from a trolley 36 carried by a bridge 31 runrling on rails 39 extending transversely of the apparatus. In its movement the trolley 36 carries the welder transversely for the welding of the abutting edges of a pair of plates. The welder 34 is of any usual electric type and may be the same as the Welder l5 of element B. The welder will desirably be made reversable so that it may be operated in either direction for accomplishing the butt-welding. l

The Welder is supplied with melt or flux from a tank 40, through a tube 4| and with wire 42 from a reel 43. 'I'he ilux tank and reel are carried with the Welder on the trolley 36 and the suction side of a fan 44 communicates with a tube leading to a head following the Welder for return of excess flux to the tank 40.

A copper bar 45 is positioned beneath the abutting edges of the plates and is adapted to be pressed up against the under side of the plates 4, 4 along the line of their abutting edges, to act asa dam, by means of a pneumatically inflated hose 46 carried in a channel member 41 filled with sand, or melt 38, which covers the hose and protects it from the heat of the weld. Tile channel is supported by an I-beam 48.

In operation of the element C, the edges of the pair of plates 4, 4, having stifeners 3 Welded to the upper surfaces thereof, are brought together in alignment over the bar 45, with their edge portions supported on the I-beams 3| and the supports 32. The supports 32 are adjusted by means 33 to provide an accurately leveled support for the edge portions of the plates, and

the feet of the blfurcated heads au of the parallel series of rams are brought. down on the upper surface of the plates, under pneumatic pressure suppliedl to the cylinders 28, to clamp the edge portions of the plates to the supports 32 and I-beams 3|.

Since the heads are bifurcated, they will straddle the stiifeners carried by the plates and permit holding of the edge portions of theplates securely to the supports 32, irrespective of the location of the stiffeners. Since the supports 32 are leveled, the heads 30, acting individually, will straighten out any irregularity in the edge portions of the plates, so that their abutting edges will be exactly level.

The Welder is then put into operation and moved from side to side of the plates to effect welding of their abutting edges.

During the welding operation, Vthe bar 45 is pressed against the bottom of the joint by the inilation of the hose 46, the hose being protected from heat by the sand or melt which covers it.

During thewelding operation the edge portion of the plates is held in position from warping by the heads 30.

The welding having been completed, the heads are elevated and the welded plates may be moved off on thebed of rollers 2, which may exand prevented i tend to any desired extent.

The operations described above may produce a finished structural element, as a bulkhead. On the other hand,'if, for example, as in the case of a bulkhead, it be desired to add further stiil'eners, as, for example, stiffeners transverse to those already applied, such may best be accomplished by hand Welding.

In use of the apparatusA and in carrying'out the method of this invention, it will be found that structural elements, as, for example, bulkheads. bottom, side andideck plate panels, etc. for ships, may be,.,.,assembled and the parts, as stiffeners.

angles to the direction of longitudinal longitudinals, or other shapes and plates, welded into an integral structure with the greatest accuracy and at a great saving in time and labor over procedure heretofore known. Y

It will be understood that the apparatus and method in accordance with this invention are contemplated as adaptable for use in the fabrication of structural elements other than those more particularly mentioned herein and that as a consequence any use for which the apparatus and method are adaptable is contemplated as within the scope of this invention. y

It-will be understood that various modification in detail may be made in the apparatus according to this invention as herein described and in the modus operandi incident to carrying out of the method as described herein in connection with the operation of the apparatus, all without departing from the scope of this invention.

The apparatus described above is not claimed herein since such forms the subject-matter of a divisional application filed by me September' 1,

1937, Serial No. 161,889.

What claim and desire Patent is:

1. A method of fabricating a structural element composed of a plate of large area carrying a multiplicity of parallel rows of shapes, which to protect by Letters comprises positioning a plate section in hori-V zontal position and tack-Welding one or more shapes thereto to hold them in proper relative position for subsequent treatment, advancing the plate section horizontally in a direction at right extension of the shape or shapes to a secon'd position, tilting the plate section in said second position at an oblique angle on an axis extending parallel to said shape or shapes, positioning a second plate section in the first named position and tack-welding a shape or shapes to the second plate section while fillet Welding the previously tack-welded shape or shapes to the first plate section, returning the rst plate section to its horizontal position, advancing the first plate section in the same horizontal direction to a third 4oblique angle on an axes extending parallel to said shape or shapes, fillet-Welding the shape or shapes thereto, and returning the plate to horizontal position, advancing the second plate section in the same horizontal direction to a third position in abutting relation with the first plate section, and butt-welding the two plate sections together.

2. A method of expediting the fabrication of a structural element composed of a plurality of abutting plate sections carrying a multiplicity of shapes, which comprises subjecting one plate section to the following successive operations, namely, applying a shape or shapes to the plate section while it is in horizontal position in one locus and holding them in xed relationship thereto by preliminarily welding them thereto throughout a minor part of their length at spaced apart intervals, then moving said plate section to a second locus and there tilting it to an oblique position and finally welding the shape or shapes thereto throughout their length and moving the plate section to a third locus; subjecting a second plate section to the same succession of operations; the first plate section being at the second locus while the second plate section is at the ilrst locus and the rst plate section being at the third locus while the second plate section all,

is at the second locus; and after the second plate section has advanced to the third locus buttwelding the rst and second plate sections.

3. A method for fabricating a structural element from a plurality'of. plates of relatively large surface area and shapes which comprises positioning and supporting each of the plates successively in a plane and tack-welding a shape to each of the plates', advancing the plates successively in substantially the original plane to a second position in substantially the original RICHARD L. BURKE. 

